Power tool dust collector

ABSTRACT

An auxiliary handle is for use with a power tool having a housing that includes a first notch and a second notch. The auxiliary handle includes a shaft, a first clamp coupled to the shaft and having a first protrusion configured to engage the first notch, and a second clamp arranged on the shaft and having a second protrusion configured to engage the second notch. When the first protrusion of the first clamp engages the first notch, the second clamp is movable along the shaft between a first position, in which the second protrusion engages the second notch, and a second position, in which the second protrusion is disengaged from the second notch. The auxiliary handle also includes a grip coupled to the shaft. When the grip is rotated relative to the second clamp, the second clamp is moved from the second position toward the first position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/718,280 filed on Dec. 18, 2019, which is a continuation ofU.S. patent application Ser. No. 15/684,671 filed on Aug. 23, 2017, nowU.S. Pat. No. 10,695,880, which is a continuation of U.S. patentapplication Ser. No. 13/604,674 filed Sep. 6, 2012, now U.S. Pat. No.9,776,296, which claims priority to U.S. Provisional Patent ApplicationNos. 61/654,296 filed Jun. 1, 2012; 61/611,417 filed Mar. 15, 2012; and61/611,003 filed Mar. 14, 2012, the entire contents of all of which areincorporated herein by reference.

U.S. patent application Ser. No. 13/604,674 is also acontinuation-in-part of U.S. patent application Ser. No. 13/349,784filed Jan. 13, 2012, now U.S. Pat. No. 8,967,923, the entire content ofwhich is incorporated herein by reference.

Further, U.S. patent application Ser. No. 13/604,674 is acontinuation-in-part of U.S. patent application Ser. No. 12/991,753filed Jan. 31, 2011, now U.S. Pat. No. 8,813,868, which is a nationalstage entry under 35 U.S.C. § 371 of International Patent ApplicationNo. PCT/US09/43365 filed May 8, 2009, which claims priority to U.S.Provisional Patent Application No. 61/051,892 filed May 9, 2008, theentire contents of all of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to power tools, and more particularly todust collectors for use with power tools.

BACKGROUND OF THE INVENTION

Dust collectors are typically used in tandem with hand-held drillingtools such as rotary hammers to collect dust and other debris during adrilling operation to prevent dust and other debris from accumulating ata worksite. Such dust collectors may be attached to a rotary hammer toposition a suction inlet of the collector proximate a drill bit attachedto the rotary hammer. Such dust collectors may also include an on-boarddust container in which dust and other debris is accumulated. Such dustcontainers are often removable from the dust collector to facilitatedisposal of the accumulated dust and debris.

SUMMARY OF THE INVENTION

The invention provides, in one aspect, an auxiliary handle for use witha power tool having a housing that includes a first notch and a secondnotch. The auxiliary handle comprises a shaft, a first clamp coupled tothe shaft and having a first protrusion configured to engage the firstnotch, a second clamp arranged on the shaft and having a secondprotrusion configured to engage the second notch, and a grip coupled tothe shaft. When the first protrusion of the first clamp engages thefirst notch and the grip is rotated relative to the second clamp, thesecond clamp is moved toward the first clamp, such that the firstprotrusion engages the first notch and the second protrusion engages thesecond notch to couple the auxiliary handle to the housing of the powertool.

The invention provides, in another aspect, an auxiliary handle for usewith a power tool having a housing that includes a first notch and asecond notch. The auxiliary handle comprises a shaft, a first clamparranged on the shaft and having a first protrusion configured to engagethe first notch, a second clamp arranged on the shaft and having asecond protrusion configured to engage the second notch, and a gripcoupled to the shaft. In response to rotation of the grip relative tothe first and second clamps, the first and second clamps are movedtoward each other, such that the first protrusion can engage the firstnotch and the second protrusion can engage the second notch to couplethe auxiliary handle to the housing of the power tool.

The invention provides, in yet another aspect, an auxiliary handle foruse with a power tool having a housing that includes a first notch and asecond notch. The auxiliary handle comprises a shaft and a first clamparranged on the shaft and having a first protrusion configured to engagethe first notch. The first clamp is movable along the shaft between afirst position in which the first protrusion engages the first notch,and a second position in which the first protrusion does not engage thefirst notch. The auxiliary handle also comprises a second clamp arrangedon the shaft and having a second protrusion configured to engage thesecond notch. The second clamp is movable between a first position inwhich the second protrusion engages the second notch, and a secondposition in which the second protrusion does not engage the secondnotch. The auxiliary handle also comprises a grip coupled to the shaft.In response to rotation of the grip relative to the first and secondclamps, the first and second clamps are respectively moved to theirfirst positions, such that the handle is coupled to the housing of thepower tool.

The invention provides, in yet another aspect, a power tool assemblycomprising a power tool having a housing that includes a first notch anda second notch, and an auxiliary handle. The auxiliary handle includes ashaft, a first clamp arranged on the shaft and having a first protrusionconfigured to engage the first notch, a second clamp arranged on theshaft and having a second protrusion configured to engage the secondnotch, and a grip coupled to the shaft. Rotation of the grip relative tothe first and second clamps causes movement of the first and secondclamps toward each other, such that the first protrusion engages thefirst notch and the second protrusion engages the second notch to couplethe auxiliary handle to the housing of the power tool.

The invention provides, in yet another aspect, an auxiliary handle foruse with a power tool having a housing that includes a first notch and asecond notch. The auxiliary handle comprises a shaft, a first clampcoupled to the shaft and having a first protrusion configured to engagethe first notch, and a second clamp arranged on the shaft and having asecond protrusion configured to engage the second notch. When the firstprotrusion of the first clamp engages the first notch, the second clampis movable along the shaft between a first position, in which the secondprotrusion engages the second notch, such that the auxiliary handle iscoupled to the housing of the power tool, and a second position, inwhich the second protrusion is disengaged from the second notch, suchthat the auxiliary handle is removable from the housing. The auxiliaryhandle further comprises a grip coupled to the shaft. When the grip isrotated relative to the second clamp, the second clamp is moved from thesecond position toward the first position.

The invention provides, in yet another aspect, a power tool assemblycomprising a power tool having a housing that includes a first notch anda second notch, and an auxiliary handle. The auxiliary handle includes ashaft, a first clamp arranged on the shaft and having a first protrusionconfigured to engage the first notch, a second clamp arranged on theshaft and having a second protrusion configured to engage the secondnotch, and a grip coupled to the shaft. Rotation of the grip relative tothe second clamp causes movement of the second clamp toward the firstclamp, such that the first protrusion engages the first notch and thesecond protrusion engages the second notch to couple the auxiliaryhandle to the housing of the power tool.

Other features and aspects of the invention will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially cutaway, perspective view of a dust collector inaccordance with an embodiment of the invention attached to a rotarypower tool.

FIG. 2 is a top view of the dust collector and rotary power tool of FIG.1.

FIG. 3 is a bottom view of the dust collector and rotary power tool ofFIG. 1.

FIG. 4 is a front view of the dust collector and rotary power tool ofFIG. 1.

FIG. 5 is a front perspective view of a dust collector in accordancewith another embodiment of the invention attached to a rotary powertool.

FIG. 6 is a rear perspective view of the dust collector and rotary powertool of FIG. 5.

FIG. 7 is a rear perspective view of the dust collector of FIG. 5attached to an opposite side of the rotary power tool.

FIG. 8 is a front perspective view of the dust collector of FIG. 5,illustrating a handle assembly having multiple size handles forattaching rotary power tools of different sizes.

FIG. 9 is an enlarged, partial cross-sectional view of an adapter foruse with any of the handles of FIG. 8.

FIG. 10 is an enlarged, front perspective view of the dust collector ofFIG. 5, illustrating a suction head rotated to a first position relativeto a suction pipe.

FIG. 11 is an enlarged, front perspective view of the dust collector ofFIG. 5, illustrating the suction head rotated to a second positionrelative to the suction pipe.

FIG. 12 is an enlarged, front perspective view of the dust collector ofFIG. 5, illustrating the suction head and a stand-alone nozzle beinginterchangeably coupled to the suction pipe.

FIG. 13 is an enlarged, exploded perspective view of the dust collectorof FIG. 5, illustrating a dust container and a filter.

FIG. 14 is a longitudinal cross-sectional view of the dust collector ofFIG. 5.

FIG. 15 is an enlarged, perspective view of the dust collector of FIG. 5exposing the rear of the telescoping suction pipe with the suction pipein an extended position.

FIG. 16 is an enlarged, perspective view of the dust collector of FIG. 5exposing the rear of the telescoping suction pipe with the suction pipein a retracted position.

FIG. 17 is an enlarged, cross-sectional view of the dust collector ofFIG. 5 illustrating an extension stop secured to the telescoping suctionpipe.

FIG. 18 is an enlarged, perspective view of the dust collector of FIG. 5illustrating a plunge depth stop with an attached ruler that are movableas a unit relative to the suction pipe.

FIG. 19 is an enlarged, cross-sectional view of the dust collector ofFIG. 5 illustrating the plunge depth stop secured to the telescopingsuction pipe.

FIG. 20 is an enlarged, perspective view of the dust collector of FIG. 5illustrating a cutaway to expose a detector that prevents attachment ofa dust container to the housing of the dust collector without anaccompanying filter.

FIG. 21 is a front perspective view of a dust collector in accordancewith yet another embodiment of the invention attached to a rotary powertool.

FIG. 22 is a rear perspective view of the dust collector and rotarypower tool of FIG. 21.

FIG. 23 is an exploded, front perspective view of the dust collector androtary power tool of FIG. 21.

FIG. 24 is a perspective view of a portion of an auxiliary handle for apower tool and a portion of a power tool according to one embodiment ofthe invention.

FIG. 25 is a partially exploded view of FIG. 24.

FIG. 26 is a side view of a grip according to one embodiment of theinvention for use with the portion of the auxiliary handle of FIG. 24.

FIG. 27 is a cross-sectional view of the grip of FIG. 26 taken alongline 4-4 of FIG. 3.

FIG. 28 is a side view of a clamp of the auxiliary handle of FIG. 24.

FIG. 29 is a cross-sectional view of the clamp of FIG. 28 taken alongline 6-6 of FIG. 5.

FIG. 30 is a side view of a rod of the auxiliary handle of FIG. 24.

FIG. 31 is a cross-sectional view of the rod of FIG. 30 taken along line8-8 of FIG. 7.

FIG. 32 illustrates the portion of the auxiliary handle of FIG. 24 inalternative positions on a power tool.

FIG. 33 is a perspective view of a power tool.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

As shown in FIGS. 1 to 4, a drilling machine or rotary power tool 1,which may configured as a percussion rotary power tool, a rotary hammer,or a hammer drill, includes a housing 2 in which a spindle (not shown)is drivable in a rotary manner about an axis of rotation 3. For thispurpose, the rotary power tool 1 includes an electric motor (also notshown), which may be connected to a remote power source via a powercable 4. Instead of the power cable 4, the rotary power tool 1 may alsobe equipped with an on-board power source such as a rechargeable batteryor a rechargeable battery pack. Since the rotary power tool 1 is thusoperated electrically, it is thus an electric rotary power tool orgenerally a power tool or electrically powered appliance.

The rotary power tool 1 is also equipped with a handle 5. It may thus beoperated by hand and accordingly be designated a hand-held rotary powertool 1. Accordingly, the rotary power tool 1 may generally be ahand-held power drill or a hand-held power tool or hand-held powermachine tool.

In the example shown, the rotary power tool 1 and its housing 2 form anL-shape, since the tool's axis of rotation 3 is aligned essentiallyperpendicularly to the axis of rotation of a rotor of the electric motorfor driving the spindle and/or the tool. In contrast to this, in the“pistol configuration” the axis of the electric motor's rotor is alignedessentially parallel to axis of rotation 3 of the tool.

With reference to FIGS. 1-3, the rotary power tool 1 is also equippedwith a chuck 6 that is drivable in a rotary manner about axis ofrotation 3 via the spindle. The chuck 6 serves to hold a tool,particularly a drilling tool, which may be a drill bit, a hammer drillbit, or a masonry drill bit. When the respective tool is in place, itrotates about the axis of rotation 3, which will also be referred to inthe following as the axis of rotation of the tool 3. Adjacent to thechuck 6, the housing 2 of rotary power tool 1 is furnished with aclamping neck 7 (FIGS. 1 and 2), which has a cylindrical shape in theillustrated embodiment. On most commercially available rotary powertools 1, the cross section of the clamping neck 7 conforms to a standardsize, for example 43 mm. The clamping neck 7 is normally used formounting an additional handle (not shown).

The rotary power tool 1 shown in FIGS. 1-4 is equipped with a dustsuction device or dust collector 8 in accordance with an embodiment ofthe invention. The dust collector 8 constitutes a separate device fromthe rotary power tool 1, and may be attached detachably to the rotarypower tool 1. Accordingly, the rotary power tool 1 may or may not beequipped with dust collector 8 depending on the requirement of theapplication.

In the mounted state shown in FIGS. 1-4, the dust collector 8 isarranged on one side of the rotary power tool 1. With reference to thenormal operating position for the rotary power tool 1, as reflected inFIGS. 1-4, the dust collector 8 is arranged to the left of the rotarypower tool 1. The dust collector 8 is expediently designed so that itmay be mounted to the right of the rotary power tool 1 in the same way.The dust collector 8 is then located entirely to the side of the rotarypower tool 1, except for a fastening device 11, which will be explainedin greater detail below, via which the dust collector 8 may be fastenedto the rotary power tool 1. The dust collector 8 is designed in such away that it may be mounted beside rotary power tool 1, and this in turnmeans that it may also be used on L-shaped rotary power tools 1 as wellas pistol-type rotary power tools 1 regardless of the size of therespective rotary power tool 1.

The dust collector 8 includes an adapter or support frame 9 and ahousing 10 that is shown in partial cutaway in FIG. 1. The support frame9 is attached to the clamping neck 7 of the rotary power tool 1 with theaid of the fastening device 11. The notable feature of this arrangementis that the dust collector 8 is fastened only to the clamping neck 7,and is only in contact with the rotary power tool 1 in the area of theclamping neck 7. As a result, the dust collector 8 may be mounted on theclamping neck 7 in the same way as an auxiliary handle, that is to sayinstead of an auxiliary handle.

Because clamping necks 7 are usually standardized in terms of shape andsize (e.g., having a diameter of about 43 mm), this also makes itpossible to mount the dust collector 8 on a wide range of differentstandard rotary power tools 1. Since there is no other contact betweenthe mounted dust collector 8 and the rotary power tool 1, the dustcollector 8 does not have to be adapted further to fit the respectiverotary power tool 1 thereby making it considerably easier to use thedust collector 8 with a range of different rotary power tools 1.Consequently, the dust collector 8 may be used on many different modelsof rotary power tools 1 since the fastening device 11 not only enablesattachment to the clamping neck 7, it also enables this attachmentwithout any other connection between the dust collector 8 and the rotarypower tool 1, so that no further adaptation has to be made between therotary power tool 1 and the dust collector 8.

With continued reference to FIG. 1, the housing 10 is attached to thesupport frame 9. For this purpose, for example, a plug-in connector 12may be conformed integrally to the housing 10, and a complementaryplug-in socket 13 may be provided on the support frame 9. In particular,the plug-in connector 12 may be plugged into the plug-in socket 13parallel to the axis of rotation of the tool 3. The shape of theconnector 12 and socket 13 is selected such that when plugged into thesocket 13 the connector 12 is held in place by a positive lock. In thiscase, a shape according to which the housing 10 is detachably attachedto the support frame 9 is particularly advantageous. For example, aretaining screw 14 may be provided to cooperate with the insertedplug-in connector 12 to secure the connector 12 in the socket 13. Thus,the retaining screw 14 may engage in the connector 12 in a positivelocking manner or it may brace the inserted connector 12 in the socket13 in a non-positive locking manner.

The connector 12 and socket 13 permit different size housings 10 to beattached to the same support frame 9. Such housings 10 may beconstructed differently, particularly with respect to a dust collectionchamber 17 (described in further detail below), for differentapplications to accommodate both large and small dust collectionchambers 17 depending upon the type of material being worked upon.

With continued reference to FIG. 1, an electric motor 15 and a suctionfan 16 are disposed in the housing 10. The electric motor 15 drives thesuction fan 16. The housing 10 also contains a dust collection chamber17. The housing 10 further accommodates a dust filter 18. The housing 10also has a power source 19 for supplying the electric motor 15 withelectrical energy. The power source 19 may be in the form of a battery,but preferably a rechargeable battery or rechargeable battery pack.

The housing 10 is also furnished with an air inlet 20 and an air outlet21, which may have the form of a plurality of slots positioned radiallyadjacent to the suction fan 16. The dust filter 18 is arranged upstreamof the suction fan 16 in a flow path leading from the air inlet 20 tothe air outlet 21. In this way, the fan 16 is protected from being hitby dirt particles and other debris. Accordingly, the dust collectionchamber 17 is also located upstream of the fan 16 and upstream of thedust filter 18.

With continued reference to FIG. 1, a straight suction pipe 22 isfastened to the support frame 9 in such manner that it is axiallyadjustable on the support frame 9. The axial direction of the suctionpipe 22 is defined by its longitudinal centreline 23, which extendsparallel to the axis of rotation of the tool 3 when the dust collector 8is mounted. As the suction pipe 22 is axially adjustable, it is possibleto adjust the dust collector 8 to match the different lengths of thetools inserted in the chuck 6. Once its position has been adjustedrelative to the support frame 9, the suction pipe 22 may be locked inposition via a locking device 24. The locking device 24 may include forexample a clip 25 that extends over the suction pipe 22 and a retainingscrew 49 for clamping the suction pipe 22 to the support frame 9.

With reference to FIGS. 1-4, a suction channel 26 is attached to thesuction pipe 22 distally with respect to the support frame 9. A firstend 27 of the suction channel 26 is coupled to an inlet end 28 of thesuction pipe 22 and is in fluid communication therewith. At the otherend, the suction channel 26 is furnished with a suction opening 29facing away from the rotary power tool 1. When the dust collector 8 ismounted, the suction opening 29 is aligned coaxially with the axis ofrotation of the tool 3. The suction opening 29 may have a circular crosssection.

The outlet end 30 of the suction pipe 22 is connected to an at leastpartly flexible tube 31, which in turn is connected to the inlet opening20 of the housing 10. The tube 31 is constructed flexibly with at leastone U-shaped curved section 32. It is practical to construct the tube 31so that the entire length thereof is flexible, that is to say fromoutlet end 30 to the air inlet 20. The tube 31 is attached detachably tothe suction pipe 22. Alternatively, the tube 31 may be attacheddetachably to the housing 10. It is also possible to attach the tube 31detachably to both the suction pipe 22 and the housing 10. Inconjunction with the housing 10 that is attached detachably to thesupport frame 9, the detachable tube 31 enables easy mounting andremoval of the housing 10 from the support frame 9. The flexibility ofthe tube 31 enables easy adaptation of the connection between thesuction pipe 22 and the inlet opening 20 when the suction pipe 22 isadjusted lengthwise.

With reference to FIG. 1, the suction pipe 22 is advantageously oftelescoping construction. For this purpose, the suction pipe 22 includesan outer pipe 33 arranged on the support frame 9 and an inner pipe 34arranged coaxially therewith and positioned inside the outer pipe 33 soas to be slidable in a telescoping manner. The inner pipe 34 carries thesuction channel 26. The outer pipe 33 is attached to the support frame 9so as to be axially adjustable and connected to tube 31. The outer pipe33 thus enables the suction pipe 22 to be adjusted axially so that thedust collector 8 may be adapted to the differing lengths of the drillingtool with which it is used, for example a drill bit, a masonry drillbit, or a hammer drill bit. The telescoping capability of the suctionpipe 22 enables the dust collector 8 to be adjusted automatically andsteplessly to the drilling depth while the rotary power tool 1 is beingoperated. As the depth of the hole created with the drilling toolincreases, so the inner pipe 34 extends deeper into the outer pipe 33.

In order to provide a dust-tight fluid coupling between the inner pipe34 and the outer pipe 33, a corrugated or expandable tube (not shown)may be provided that folds together like an accordion when the innerpipe 34 advances into the outer pipe 33, and unfolds in the manner of anaccordion when the inner pipe 34 is withdrawn from the outer pipe 33.

As shown in FIG. 2, the inner pipe 34 may be braced axially against theouter pipe 33 via a compression spring 35. In this way, the inner pipe34 is pre-tensioned outwardly. As a consequence, the suction channel 26is pre-tensioned when the suction opening 29 thereof comes into contactwith the obstruction to be drilled. The compression spring 35 mayparticularly be integrated in the corrugated tube described above.

In order to be able to switch on the dust collector 8 manually, it maybe equipped with a button switch 36 (FIGS. 1 and 3) that is operablemanually, for example by rotating, pressing or sliding, and which isattached to housing 10. In addition or alternatively, as shown in FIG.2, a pressure switch 37 may be provided that switches on the dustcollector 8 automatically when the suction channel 26 is pressed againstan obstruction or a workpiece that is to be drilled. Actuation of therespective switches 36 or 37 energizes the electric motor 15 and thuscauses the fan 16 to activate. In the illustrated embodiment of the dustcollector 8, the pressure switch 37 is arranged axially between thecompression spring 35 and the outer pipe 33. However, the pressureswitch 37 might also be arranged axially between the compression spring35 and the inner pipe 34, for example.

In the illustrated embodiment of the dust collector 8, at least threeswitching positions are assigned to the button switch 36. In a firstswitching position, the electric motor 15 and fan 16 may be manuallyswitched off or deactivated irrespective of actuation of the pressureswitch 37, so that the fan 16 cannot be activated by operating thepressure switch 37. In a second switching position, the pressure switch37 is activated so that the fan 16 may be switched on and off by theoperating pressure switch 37. In other words, in the second switchingposition, the electric motor 15 and fan 16 may be activated anddeactivated automatically in response to actuation of the pressureswitch 37. In a third switching position, the electric motor 15 and fan16 may be switched on or activated manually regardless of the pressureswitch 37 being operated. In other words, in the third switchingposition, the electric motor 15 may be activated manually irrespectiveof actuation of the pressure switch 37. Therefore, when the buttonswitch 36 is toggled to the third switching position, the dust collector8 may be used as a stand-alone suction or vacuum device when it isdetached from the rotary power tool 1. The first, second, and thirdswitching positions may occur in any sequential order depending upon theconfiguration of the switch 36.

With reference to FIG. 1, the fastening device 11, which is used tosecure the dust collector 8 to the rotary power tool 1, has a band clamp38. The band clamp 38 encircles the clamping neck 7 coaxially with theaxis of rotation of the tool 3 to enable the dust collector 8 to bemounted on the rotary power tool 1. The fastening device 11 is alsofurnished with a clamping device 39 (FIG. 3), that enables the bandclamp 38 to be tightened when it is in place around the clamping neck 7.Tightening the clamp band 38 then creates a non-positive lockingengagement securing the support frame 9 on the clamping neck 7. Theclamping device 39 may be equipped with a manually operable toggle lever40 that may be used to tighten the band clamp 38. The toggle lever 40 isdesigned as an additional or auxiliary handle, as is shown particularlyclearly in FIG. 4.

The fastening device 11 may be designed for a specific cross section ofthe clamping neck 7, for example for a standard circular cross sectionwith a 43 mm diameter.

In the illustrated embodiment of the dust collector 8, the housing 10 isalso furnished with a housing section 41 that is constructed in the formof an additional handle (FIG. 1). This housing section 41 contains theelectric motor 15 and the power source 19. The dust collector 8described here may thus particularly advantageously offer two additionalhandles for the rotary power tool 1, that is to say the toggle lever 40and the housing section 41, which helps considerably to ease theoperation of the rotary power tool 1. The housing section 41 extendsessentially perpendicularly to the longitudinal centreline 23 of thesuction pipe 22.

The dust filter 18 may be designed as a fine dust filter. Such a finedust filter, which may also be referred to as a HEPA filter (HighEfficiency Particulate Absorber), is able to trap at least 99.97% ofparticles 0.3 microns and smaller that are typically generated duringdrilling. In this way, not only is the fan 16 protected from being hitby larger particles but fine dust is also prevented from contaminatingthe area surrounding the rotary power tool 1, thereby reducing thehazard to the health of the operator using it. The dust filter 18 mayinclude a standard filter medium such as a fleece material or a papermaterial.

In order to prevent the dust filter 18 from being damaged by the impactof larger particles as well, an impactor 42 (FIG. 1) may be arranged inthe flow path and upstream of the dust filter 18 in the housing 10. Theimpactor 42 forms a collision plate that is arranged in the flight pathof the airborne particles, in the area of the air outlet 20 anddownstream of an outlet end 43 of the tube 31. The impactor 42 causes apowerful flow diversion of the arriving suction stream, causing itinitially to be directed away from the dust filter 18. The impactor 42diverts the arriving stream into the dust collection chamber 17. Oncethere, the stream must then be redirected again so that it reaches thesuction side of the fan 16 through the dust filter 18. In this way, itis possible to prevent the dust filter 18 from being bombarded directlyby the particles carried along in the airflow. At the same time, theairborne particles are subjected to a powerful decelerating force, thusenabling them to accumulate more easily in the dust collection chamber17.

The dust collection chamber 17 is defined at least partially by acollection container 44 (FIG. 1). The collection container 44 is aseparate component from the housing 10 and is attached detachably to thehousing 10. Together, the housing 10 and the collection container 44define the dust collection chamber 17. Because the collection container44 is detachable, the dust collection chamber 17 may be emptied veryeasily. Moreover, different collection containers 44 may be selected forattachment to the housing 10. For example, the comparatively smallcollection container 44 shown is suitable for collecting rock wastematerial that is created when drilling in concrete or rock. However, ifthe rotary power tool 1 is to be used for drilling wood, a considerablylarger dust collection chamber 17 is required and a correspondinglylarger collection container or collecting pouch or bag may accordinglybe attached to the housing 10.

It is particularly advantageous to make the collection container 44 froma relatively hard and/or rigid plastic, which is practically designed sothat the collection container 44 is not noticeably deformed due to thevacuum generated in the dust collection chamber 17 when the dustcollector 8 is being operated.

The housing 10 may also be made such that it is at least partlytransparent to visible light at least in the area of the dust collectionchamber 17. For example, the housing 10 may be furnished with atransparent window in the area of the dust collection chamber 17 to viewthe accumulated height of the dust and other debris within the chamber17. If, as here, a collection container 44 is used the container 44 maybe made to be entirely transparent for the same purpose. The collectioncontainer 44 may equally contain at least one transparent window, andthe rest of the container 44 may be non-transparent or opaque. Thehousing 10 is advantageously made from a plastic for this purpose. Ifthe housing 10 and/or collection container 44 includes transparent andnon-transparent areas, the housing 10 and the collection container 44may be manufactured using different plastics.

Unlike the housing 10, the support frame 9 is advantageously made frommetal, a lightweight metal or lightweight metal alloy being preferred.Aluminium or an aluminium alloy is particularly suitable for thepurpose.

If the power source 19 is configured as a rechargeable battery orrechargeable battery pack, as here, it may be fitted detachably to thehandle-shaped section 41 in the housing 10. In this way, it is possiblefor example to charge the power source 19 using a separate charger. Thisalso makes it possible to use several power sources 19 in an alternatingmanner.

The suction channel 26 may be disposed on the suction pipe 22 so as tobe rotatable about the longitudinal centerline 23 of the suction pipe22. A locking device 45 (FIG. 1) may be provided between the suctionchannel 26 and the suction pipe 22 to lock the suction channel 26 in agiven rotated position. The locking device 45 may be, for example, asetscrew for locking the sleeve-like end 27 relative to the suction pipe22, or the inner pipe 34 thereof, to assure a non-positive lock at thedesired rotated position.

The suction channel 26 may have a screen 46 on a side facing away fromthe suction opening 29, which is facing towards the viewer in FIG. 1.The screen 46 has a screen aperture 47, the size of which is adjustable,through which a tool bit is received. When the dust collector 8 ismounted on the rotary power tool 1, the screen aperture 47 is positionedcoaxially with the axis of rotation of the tool 3. The respectivedrilling tool passes through the screen opening 47 as far as the suctionopening 29. Because the screen aperture 47 is adjustable, the suctionchannel 26 may be adapted to accommodate the various diameters of thedrilling tools used. For example, the screen 46 is equipped with anadjusting ring 48 that may be used to adjust the opening size of thescreen aperture 47. The adjusting ring 48 may be turned manually tochange the opening size of the screen aperture 47.

The suction channel 26 has a predefined length that is synchronized withthe distance between the axis of rotation of the tool 3 and thecenterline axis of the suction pipe 22, which is adjusted when the dustcollector 8 is mounted on a rotary power tool 1 having a standardclamping neck 7 cross section to which the dust collector 8 is adapted.To enable other cross sections of the clamping neck 7 as well, inanother embodiment of the dust collector 8, the suction channel 26 mayalso be designed so that its length is adjustable.

The dust collector 8 is designed such that it may be operated using anon-board power source and mounted on the rotary power tool 1 in such waythat when mounted it is positioned next to the rotary power tool 1 in atypical working position of the rotary power tool 1, and spaced apartfrom the rotary power tool 1 by the fastening device 11 such that thedust collector 8 does not otherwise touch or contact the rotary powertool 1.

FIGS. 5 and 6 illustrate a dust collector 110 in accordance with anotherembodiment of the invention for use with a hand-held rotary power tool114 (e.g., a rotary hammer). As will be described in more detail below,the dust collector 110 is operable to collect dust and other debris froma workpiece during a drilling and/or hammering operation performed bythe power tool 114 to maintain the user's work area substantially clearof dust.

The dust collector 110 includes a housing 118, a telescoping suctionpipe 122 coupled to the housing 118, an electric motor 126 positioned inthe housing 118 (FIG. 14), a suction fan 130 driven by the electricmotor 126 and operable to generate a vacuum in the suction pipe 122, anda dust container 134 coupled to the housing 118 and positioned upstreamof the suction fan 130. With reference to FIGS. 5 and 7, the dustcollector 110 includes a handle assembly 138 that supports the powertool 114 in a side-by-side relationship with the dust collector 110.Particularly, the handle assembly 138 may be attached to either side ofthe housing 118 depending upon which side of the dust collector 110 theuser wants to position the power tool 114.

With reference to FIG. 8, the handle assembly 138 includes multiplehandles 142 a, 142 b, 142 c having respective head portions 146 a, 146b, 146 c of a different size to accommodate power tools 114 ofcorresponding sizes, and respective adapters 150 a, 150 b, 150 c forsecuring the handles 142 a-142 c to the housing 118. In the illustratedembodiment of the handle assembly 138, three handles 142 a-142 c areshown each having a head portion 146 a-146 c of a different size inwhich a corresponding sized neck 154 on the power tool 114 is clamped.Alternatively, the handle assembly 138 may include more or fewer handles142 a-142 c of different sizes. Each of the handles 142 a-142 c includesa cylindrical band 158 a, 158 b, 158 c that is constricted and expandedby rotating a grip 162 on the handle 142 a-142 c in opposite directions.The bands 158 a, 158 b, 158 c include different circumferential lengthsto accommodate power tools 114 having corresponding sized necks 154. Theadapters 150 a-150 c each include an arcuate slot 166 in which a portionof the band 158 a-158 c is received (FIG. 9). Accordingly, the adapters150 a-150 c are connected to the head portions 146 a-146 c as a unit. Inan alternative embodiment of the handle assembly 138, only a single grip162 may be provided for interchangeable use with any of the headportions 146 a-146 c. For example, to exchange any of the handles 142a-142 c for another, the grip 162 may be unthreaded from one of the headportions 146 a-146 c and threaded to another of the head portions 146a-146 c.

With continued reference to FIG. 9, the adapter 150 includes a fixedclamp member 170 and an opposed, movable clamp member 174 for clampingthe adapter 150 to either side of the housing 118. Particularly, thefixed clamp member 170 is received within a first notch 178 in thehousing 118, and the movable clamp member 174 is received within asecond notch 182 in the housing 118. The notches 178, 182 are defined ineach side of the housing 118 to clamp the adapter 150 to either side ofthe housing 118. In the illustrated embodiment of the dust collector110, a metal reinforcing plate 183 is insert molded with the housing 118between the notches 178, 182 such that the clamp members 170, 174 engagebottom and top edges 184, 185 of the plate 183, respectively.Alternatively, the plate 183 may be omitted.

The adapter 150 also includes a cam 186 and a follower 190 for actuatingthe movable clamp member 174 between an open position in which it isdisplaced from the second notch 182 and disengaged from the housing 118,and a closed position in which the movable clamp member 174 is receivedwithin the second notch 182 and engaged with the housing 118 (FIG. 9).In the illustrated embodiment of the adapter 150, the cam 186 isintegrally formed as a single piece with a lever 194, and the follower190 is integrally formed as a single piece with the movable clamp member174. The adapter 150 further includes a resilient member (e.g., acompression spring 198) that biases the movable clamp member 174 awayfrom the fixed clamp member 170 and toward the open position.

The handles 142 a-142 c are sized to maintain a generally consistentspacing between parallel axes 202, 206 of the power tool 114 and thedust collector 110, respectively (FIG. 8) so that a tool bit 210attached to a chuck 214 of the power tool 114 (FIGS. 5-7), irrespectiveof the size of the particular power tool 114 used with the dustcollector 110, is positioned in the same location relative to the dustcollector 110.

With continued reference to FIGS. 5-7, the dust collector 110 and thepower tool 114 include respective power tool battery packs 218, 222,each of which may be interchangeably coupled with the power tool 114 andthe dust collector 110 for separately powering the power tool 114 andthe dust collector 110, respectively. In other words, the dust collector110 and the power tool 114 may be independently powered using identicalbattery packs 218, 222. Such battery packs 218, 222 may be 12-volt powertool battery packs 218, 222 that include three lithium-ion batterycells. Alternatively, the battery packs 218, 222 may each include feweror more battery cells to yield any of a number of different outputvoltages (e.g., 14.4 volts, 18 volts, etc.). Additionally oralternatively, the battery cells may include chemistries other thanlithium-ion such as, for example, nickel cadmium, nickel metal-hydride,or the like.

With reference to FIG. 14, the battery pack 218 is removably coupled tothe dust collector 118 housing along an axis 226 that is orientedsubstantially normal to the axis 206 of the dust collector 110. As such,the battery pack 218 is substantially isolated from the axial impactsimparted by the power tool 114 along the power tool axis 202. In analternative embodiment of the dust collector 110 in which such axialimpacts imparted by the power tool 114 are not of concern, the batterypack 218 may be oriented substantially parallel with the axis 206 of thedust collector 110.

With reference to FIGS. 5-7, the dust collector 110 includes a suctionhead 230 coupled to the end of the suction pipe 122. The suction head230 includes a hub 234, a hollow arm 238 extending from a side of thehub 234, and a shroud 242 coupled to the end of the arm 238. In theillustrated embodiment of the dust collector 110, the arm 238 includes afirst portion 243 integrally formed with the hub 234 and a secondportion 244 integrally formed with the shroud 242 (FIG. 12). The secondportion 244 is received in the first portion 243 by way of a snap-fit;however, the second portion 244 may be retained to the first portion 243in any of a number of different ways.

The shroud 242 defines a stepped suction inlet 246 (FIG. 5) throughwhich air is drawn in during operation of the dust collector 110. Whenthe suction inlet 246 is in contact with a workpiece during a drillingoperation, the shroud 242 encloses a portion of the tool bit 210 and thesurrounding region of the work piece to maintain the region at asub-atmospheric pressure. In other words, the vacuum created in thesuction pipe 122 and the suction head 230 draws dust and other debrisgenerated during the drilling and/or hammering operation from the shroud242, through the suction pipe 122, for depositing in the container 134.

As shown in FIGS. 10 and 11, the suction head 230 may be attached to thesuction pipe 122 in two different orientations to accommodate placementof the power tool 114 on both sides of the dust collector 110. A detentarrangement 250 is utilized to maintain the suction head 230 in eitherof the positions shown in FIGS. 10 and 11. Particularly, the detentarrangement 250 includes two detent members 254 formed on the arm 238and two detent recesses 258 located on opposite sides of the suctionpipe 122 (with respect to the axis 206). In the illustrated embodimentof the detent arrangement 250, the detent members 254 are radiallyextending ribs integrally formed with the arm 238, and the detentrecesses 258 are defined in an end cap 262 attached to the end of thesuction pipe 122. When the detent members 254 are received in theirrespective recesses 258, the suction head 230 is rigidly maintained inposition. To re-orient the suction head 230 from one side of the suctionpipe 122 to the other, the user of the dust collector 110 needs only toapply a slight torque or a rotational force to the suction head 230 toovercome the friction between the detent members 254 and the end cap 262for removing the detent member 254 from its respective detent recess258. Alternatively, the detent arrangement 250 may be configured in anyof a number of different ways for securing the suction head 230 in thepositions shown in FIGS. 10 and 11.

With reference to FIG. 12, the dust collector 110 includes a nozzle 266interchangeably coupled to the suction pipe 122 with the suction head230. Particularly, the nozzle 266 includes a hub 270 having an identicalconfiguration as the hub 234 of the suction head 230. As such, thenozzle 266 is attachable and removable from the suction pipe 122 in thesame manner as the suction head 230. As is described in more detailbelow, the nozzle 266 facilitates usage of the dust collector 110without the power tool 114 as a stand-alone vacuum device.

With reference to FIGS. 18 and 19, the dust collector 110 includes aplunge depth stop 274 movable along the length of the suction pipe 122and selectively fixed to the suction pipe 122 to limit the extent towhich the suction pipe 122 may telescope relative to the housing 118.The suction pipe 122 includes a rail 278 along which the depth stop 274is movable, and a detent plate 282 including spaced apertures 286 alongthe length of the plate 282 is received within the rail 278. The depthstop 274 includes a pin 290 (FIG. 19) that is receivable in one of theapertures 286 in the detent plate 282 to secure the depth stop 274 tothe suction pipe 122, and an actuator 294 for selectively moving the pin290 relative to the detent plate 282 for inserting and removing the pin290 from one of the apertures 286. The pin 290 is normally biased awayfrom the detent plate 282 by a resilient member (e.g., a compressionspring 298). Likewise, the actuator 294 is normally biased upward fromthe frame of reference of FIG. 19 by a resilient member (e.g., acompression spring 302). The actuator 294 includes a cam profile 306which, in response to the actuator 294 being released from an initialdepressed position, displaces the pin 290 toward the detent plate 282against the bias of the spring 298. To reposition the depth stop 274relative to the suction pipe 122, the actuator 294 is depressed againstthe bias of the spring 302 until the cam profile 306 is aligned with thepin 290, thereby permitting the pin 290 to be pushed away from thedetent plate 282 (thereby removing the pin 290 from one of the apertures286) by the spring 298.

With reference to FIG. 18, the dust collector 110 also includes a ruler310 coupled for movement with the depth stop 274. As such, the plungedepth of the suction tube 122 may be set with reference to markings onthe ruler 310 and a reference datum 312 on the housing 118 (e.g., a lineor edge on the front of the housing 118 surrounding the suction pipe122). For example, should the user of the dust collector 110 and thepower tool 114 desire to plunge the tool bit 210 only two inches into aworkpiece, the user would slide the depth stop 274 relative to thesuction tube 122 until the “2 inch” marking on the ruler 310 is inalignment with the reference datum 312 on the housing 118. Thereafter,the suction pipe 122 is limited to retracting only two inches into thehousing 118 before the depth stop 274 contacts the housing 118 at whichtime further retraction of the suction pipe 122 is halted.

With reference to FIG. 15, the dust collector 110 includes an extensionstop 314 movable along the length of the suction pipe 122 andselectively fixed to the suction pipe 122 to limit the extent to whichthe suction pipe 122 may extend from the housing 118 (i.e., bycontacting an interior surface of the housing 118). Particularly, theextension stop 314 is nearly structurally identical to the plunge depthstop 274 and therefore may be selectively secured along the rail 278 ofthe suction tube 122 in a similar manner as the plunge depth stop 274.However, the extension stop 314 includes a two-piece actuator 318 with afirst portion 322 (which includes the cam profile) being attached withthe remainder of the extension stop 314 to the suction pipe 122 fortelescoping movement with the suction pipe 122, and a second portion 326that is stationary on the housing 118. The second portion 326 includes aplunger 330 that is engageable with the first portion 322 to release theextension stop 314 from the suction pipe 122. A resilient member (e.g.,a compression spring 334) biases the second portion 326 of the actuator318 upward from the frame of reference of FIG. 15 such that the secondportion 326 is normally clear of the remainder of the extension stop 314as the stop 314 moves with extension and retraction of the suction pipe122.

With reference to FIGS. 15 and 16, the dust collector 110 furtherincludes a first switch 338 electrically connecting the motor 126 with apower source (e.g., the battery pack 218) to activate the motor 126 inresponse to detecting telescoping movement of the suction pipe 122relative to the housing 118. The dust collector 110 also includes acontroller (not shown) electrically connected between the switch 338 andthe battery pack 218, and a second switch 342 (FIG. 6) electricallyconnected with the motor 126, the battery pack 218, and the first switch338 via the controller. The second switch 342 is toggled between a firstswitching position in which the electric motor 126 remains deactivatedirrespective of actuation of the first switch 338, a second switchingposition in which the electric motor 126 may be activated anddeactivated automatically in response to actuation of the first switch338, and a third switching position in which the electric motor 126 maybe activated irrespective of actuation of the first switch 338. In theillustrated embodiment of the dust collector 110, the second switch 342is configured as a slide switch. Alternatively, the second switch 342may be configured in any of a number of different ways to accommodatethe first, second, and third switching positions. The second switch 342may be toggled to either of the first switching position or the thirdswitching position when using the dust collector 110 as a stand-aloneunit in conjunction with the stand-alone nozzle 266 shown in FIG. 12.The first, second, and third switching positions of the second switch342 may occur in any sequential order depending upon the configurationof the switch 342.

In the illustrated embodiment of the dust collector 110 shown in FIG.15, with the second switch 342 toggled to the second or “automatic”switching position, the first switch 338 (e.g., a microswitch configuredas a normally closed switch) is maintained in an open state whencontacted by the extension stop 314. As such, the controller will notsupply current from the battery pack 218 to the motor 126 to activatethe motor 126 so long as the suction pipe 122 is fully extended from thehousing 118, at least to an extent permitted by the extension stop 314.However, in response to the suction pipe 122 retracting into the housing118 (which is indicative of the start of a drilling operation by thepower tool 114), the first switch 338 detects this movement when itloses contact with the extension stop 314, thereby actuating the firstswitch 338 to a closed state. The controller then supplies current fromthe battery pack 218 to the motor 126 to activate the motor 126 to drawa vacuum through the suction pipe 122 and the suction head 230 as longas the suction pipe 122 remains in a retracted position relative to thehousing 118.

In a first manner of operating the dust collector 110, the controllerinitiates a timer upon the first switch 338 detecting movement of thesuction pipe 122 from the fully extended position to a retractedposition. If the suction pipe 122 is maintained in a retracted positionfor a predetermined amount of time (e.g., at least one second), thecontroller maintains activation of the motor 126 for anotherpredetermined amount of time (e.g., four seconds) subsequent to thesuction pipe 122 returning to its fully extended position so that dustand other debris within the suction pipe 122 may be cleared anddeposited in the dust container 134 after completion of a drillingoperation and removal of the dust collector 110 from the workpiece. Ifthe suction pipe 122 is not maintained in a retracted position for atleast one second, for example, the controller immediately deactivatesthe motor 126 in response to the suction pipe 122 returning to its fullyextended position.

In a second manner of operating the dust collector 110, rather thanimmediately activating the motor 126 in response to retraction of thesuction pipe 122, the controller initiates a timer upon the first switch338 detecting movement of the suction pipe 122 from the fully extendedposition to a retracted position. The controller activates the motor 126only after a predetermined amount of time (e.g., a fraction of a second)lapses with the suction pipe 122 maintained in the retracted position.As a result, inadvertent “bumps” or contact with the suction pipe 122that might otherwise cause slight retraction of the suction pipe 122 areignored by the controller, thereby maintaining the motor 126 in adeactivated state and conserving power in the battery pack 218.

Also, rather than immediately deactivating the motor 126 when thesuction pipe 122 is returned to its fully extended position, thecontroller maintains activation of the motor 126 for a period of time(e.g., a fraction of a second or more) in response to the first switch338 resuming contact with the extension stop 314, at which time thefirst switch 338 is actuated to an open state. As a result, dust andother debris within the suction pipe 122 may be cleared and deposited inthe dust container 134 after completion of a drilling operation andremoval of the dust collector 110 from the workpiece.

With reference to FIG. 13, the dust collector 110 includes a filter 346supported by at least one of the housing 118 and the dust container 134.In the illustrated embodiment of the dust collector 110, the filter 346includes a plastic housing 348, a pleated element 350 within the housing348, and a rim 354 surrounding the pleated element 350. The rim 354 istrapped between the dust container 134 and the housing 118 when the dustcontainer 134 is attached to the housing 118. Alternatively, the dustcollector 134 may incorporate additional structure for securing thefilter 346 to the dust container 134 prior to the dust container 134being attached to the housing 118. When the dust container 134 isremoved from the housing 118, the filter 346 is accessible and removablefrom the dust container 134 for servicing and/or replacement by merelypulling the filter 346 (by, for example, grasping the rim 354) from thedust container 134 after the dust container 134 has been removed ordetached from the housing 118. The filter 346 may be configured as ahigh efficiency particulate air (“HEPA”) filter 346.

With reference to FIG. 14, the filter 346 is oriented within the dustcontainer 134 in an inclined or an oblique manner relative to the axis206 of the dust collector 110. As such, it is expected that at least aportion of the filter 346 will remain exposed when the dust container134 is nearly filled with dust, regardless of the orientation of thedust collector 110 while in use. Particularly, the pleated element 350of the filter 346 extends into the interior of the dust container 134,and at least a portion of the pleated element 350 is expected to remainexposed when the dust container 134 is nearly filled with dust,regardless of the orientation of the dust collector 110 while in use.Optionally, the dust collector 110 may include a secondary filter (e.g.,a porous plate, a screen, etc.) positioned between the fan 130 and thefilter 346 to inhibit particles that may have bypassed the filter 346from being impacted by the fan 130. Such a secondary filter may bepermanently affixed to the housing 118 and non-removable from thehousing 118. Such a secondary filter may also include a fine pore size,such that any particles bypassing both the filter 346 and the secondaryfilter are sufficiently small to not damage the fan 130.

With reference to FIG. 20, the dust collector 110 includes a detector358 coupled to the housing 118 and biased toward a first position inwhich a first arm 362 of the detector 358 protrudes from the housing 118to prevent the dust container 134 from being coupled to the housing 118in absence of the filter 346. The first arm 362 is retractable into thehousing 118 in response to the detector 358 being moved to a secondposition by the filter 346 when the filter 346 is present, therebypermitting the container 134 to be coupled to the housing 118.Particularly, in the illustrated embodiment of the dust collector 110,the detector 358 is pivotably supported by the housing 118 at a locationupstream of the suction fan 130. The detector 358 includes a shaft 366defining a rotational axis 370 about which the detector 358 ispivotable, the first arm 362 that extends radially from the shaft 366, afinger 374 positioned adjacent the first arm 362, and a second arm 378that extends radially from the shaft 366 and that is axially spaced fromthe first arm 362. The detector 358 is configured as a single, unitarycomponent. Alternatively, the various features of the detector 358,including the first arm 362, the second arm 378, and the finger 374, maybe separate from each other.

The first arm 362 is located on the shaft 366 such that the first arm362 is generally aligned with one of the segments of the rim 354 whenthe filter 346 is situated in an installed position in the dustcontainer 134. As such, when the pre-assembled filter 346 and dustcontainer 134 are moved into position for attachment to the housing 118,the first arm 362 is engaged by the rim 354, therefore causing thedetector 358 to pivot about the axis 370. A resilient member (e.g., acompression spring, not shown) is positioned between the housing 118 andthe second arm 378 for biasing the detector 358 to a position in whichthe first arm 362 protrudes from the housing 118 in absence of thefilter 346.

With continued reference to FIG. 20, the finger 374 is in alignment witha window or an aperture 382 in the housing 118 through which analignment 386 tab on the dust container 134 is receivable when thepre-assembled filter 346 and dust container 134 are attached to thehousing 118. In absence of the filter 346 and dust container 134, thespring biases the finger 374 to a pivoted position in which it at leastpartially protrudes into the aperture 182. Should the user of the dustcollector 110 attempt to attach the dust container 134 without thefilter 346 being in position, the spring will maintain the shaft 366 ina pivoted position in which the first arm 362 protrudes from the housing118 and the finger 374 at least partially protrudes into the aperture382. As such, the finger 374 prevents the alignment tab 386 from beingreceived in the aperture 382, thereby preventing attachment of the dustcontainer 134 to the housing 118.

However, when the pre-assembled filter 346 and dust container 134 aremoved into position for attachment to the housing 118, the first arm 362is engaged by the rim 354, thereby causing the shaft 366 to pivot aboutthe axis 370 and remove the finger 374 from the aperture 382. Thealignment tab 386 on the dust container 134 may then be fully receivedwithin the aperture 382 for attaching and subsequently securing the dustcontainer 134 to the housing 118.

FIGS. 21 and 22 illustrate a dust collector 410 in accordance with yetanother embodiment of the invention for use with a hand-held rotarypower tool 414 (e.g., a hammer drill). The dust collector 410 issubstantially identical to the dust collector 110 described above andshown in FIGS. 5-20. As such, like components and features areidentified with like reference numerals plus “300.”

The dust collector 410 includes an adapter 450 and an auxiliary handle442 for supporting the power tool 414 in a side-by-side relationshipwith the dust collector 410 (FIGS. 21 and 22). The adapter 450 includesa fixed clamp member 470 and an opposed, movable clamp member 474 forclamping the adapter 450 to either side of the housing 418 (FIG. 23).Particularly, the fixed clamp member 470 is received within a firstnotch 482 in the housing 418, and the movable clamp member 474 isreceived within a second notch 478 in the housing 418 (FIG. 22). Thenotches 478, 482 are defined in each side of the housing 418 to clampthe adapter 450 to either side of the housing 418. With reference toFIG. 23, the adapter 450 also includes a cam 486 and a follower 490 foractuating the movable clamp member 474 between an open position in whichit is displaced from the second notch 478 and disengaged from thehousing 418, and a closed position in which the movable clamp member 474is received within the second notch 478 and engaged with the housing418. In the illustrated embodiment of the adapter 450, the cam 486 isintegrally formed as a single piece with a lever 494, and the follower490 is integrally formed as a single piece with the movable clamp member474. The adapter 450 further includes a resilient member (e.g., acompression spring 498) that biases the movable clamp member 474 awayfrom the fixed clamp member 470 and toward the open position.

With continued reference to FIG. 23, the handle 442 includes a shaft 500extending from the adapter 450, a clamp member 504 movable along andrelative to the shaft 500, a grip 508 having a threaded insert 512engageable with a threaded portion 516 of the shaft 500, and a spacer520 positioned between the movable clamp member 504 and the grip 508.The adapter 450 includes a fixed clamp member 524 opposite and in facingrelationship with the movable clamp member 504. The clamp members 504,524 are received in corresponding notches 528, 532 in a portion of thepower tool 414 (e.g., a transmission housing 536) to thereby clamp thepower tool 414 between the movable clamp member 504 and the fixed clampmember 524. Particularly, as the grip 508 is threaded to the shaft 500(i.e., via the threaded insert 512), the spacer 520 displaces themovable clamp member 504 along the shaft 500 toward the fixed clampmember 524, thereby progressively increasing the clamping force exertedon the power tool 414.

With reference to FIGS. 21 and 22, the dust collector 410 also includesa suction head 530 longer than that shown in the dust collector 10 ofFIGS. 5 and 6 to account for a greater distance between the parallelaxes 502, 506 of the power tool 414 and the dust collector 410.Particularly, the hub 534 and first arm portion 443 of the suction head530 are used with a shroud 542 having an elongated second arm portion444. In other words, the second arm portion 444 of the suction head 530is longer than that of the suction head 230 shown in FIGS. 5 and 6. Thesecond arm portions 244, 444 with accompanying shrouds 242, 542 may beinterchanged by manipulating the snap-fit between the arm portions 243,244 and 443, 444 depending upon what type of power tool with which thedust collector 410 is used (i.e., the rotary hammer of FIGS. 5 and 6 orthe hammer drill of FIGS. 21 and 22). Alternatively, the first armportion 243, 244 may include multiple (i.e., at least two) detentrecesses 245 (FIG. 12) with which to use with the snap-fit between thearm portions 243, 244 and 443, 444 depending upon what type of powertool with which the dust collector 410 is used (i.e., the rotary hammerof FIGS. 5 and 6 or the hammer drill of FIGS. 21 and 22). Accordingly,the arm portions 244, 444 may telescope relative to the arm portions243, 443 in particular increments determined by the spacing between thedetent recesses 245 to lengthen or shorten the suction heads 230, 530.

FIGS. 24-25 illustrate an auxiliary or side handle 1020 according toanother embodiment of the invention. The illustrated side handle 1020 isremovably coupled to a power tool, such as, a hammer drill, to provide asecond location on the power tool for a user to grasp and hold the powertool. For example, in some embodiments, the power tool may include apistol-shaped housing that a user holds with one hand during operation.Such a power tool 1022 is illustrated in FIG. 33. The illustrated powertool 1022 of FIG. 33 is a drill that includes a housing 1024 having ahandle end 1026 and a chuck end 1028. The housing 1024 forms a mainhandle 1030 at the handle end 1026 and a chuck 1032 extends from thechuck end 1028, and is configured to couple a tool, such as a drill bitor the like, to the drill 1022 along a chuck axis 1034. An actuator 1035is positioned adjacent the main handle 1030. The actuator 1035 isoperable by the user to operate the chuck 1032, e.g., rotate the chuck1032, and thereby rotate the tool held by the chuck 1032.

With reference to the first embodiment of the side handle 1020, which isillustrated in FIGS. 24-33, only a portion of the power tool housing isillustrated, which is a gear casing 1033. However, the sidle handle 1020may be coupled to other portions of the power tool housing. Asillustrated in FIG. 24, when the side handle 1020 is coupled to orengaged with the gear casing 1033, the side handle 1020 extends in adirection generally perpendicular relative to the axis 1034 that extendsthrough a motor, a drive mechanism, a chuck, and a working piece (e.g.,a drill bit, a saw blade, a screwdriver bit, etc.) of the power tool.

The illustrated gear casing 1033 defines four apertures 1036, 1037,1038, 1039 (FIG. 32), which are notches, formed in the gear casing 1033.Alternatively, as illustrated in FIG. 32, the apertures 1036-1039 may beformed in a separate ring 1040 that is supported on the power tooladjacent to a clutch ring (not shown). In other embodiments, theapertures 1036-1039 may be formed in other suitable locations ondifferent types of power tools.

The illustrated first and second apertures 1036, 1037 are formed in anupper portion of the gear casing 1033, while the third and fourthapertures 1038, 1039 are formed in a lower portion of the gear casing1033. The gear casing 1033 includes two nose portions 1042 adjacent eachof the first and second apertures 1036, 1037 such that the side handle1020 may be repositioned relative the power tool (i.e., the side handle1020 may extend outwardly to the left or to the right of the gear casing1033). Further, the gear casing 1033 includes two nose portions 1042adjacent each of the third and fourth apertures 1038, 1039 such that theside handle 1020 may be oriented in additional positions relative to thegear casing 1033. For example, the side handle 1020 may extend upward ordownward from the gear casing 1033 or extend outwardly to the left orright from the lower portion of the gear casing 1033. The nose portions1042 extend partially over the apertures 1036-1039 to inhibit the sidehandle 1020 from separating or being pulled apart from the power tool orgear casing 1033 after the side handle 1020 is tightened in place orcoupled to the power tool.

The side handle 1020 includes a grip 1044 (FIG. 26), a first clamp 1046,a second clamp 1048, a rod 1050, and a sleeve 1052. The first clamp 1046and the second clamp 1048 are configured to be received in two adjacentapertures 1036-1039 of the power tool 1022 to connect or couple the sidehandle 1020 to the power tool 1022. The rod 1050 extends through thefirst and second clamps 1046, 1048 and is threadably engaged with thegrip 1044. The rod 1050 also extends through the sleeve 1052, and thesleeve 1052 is positioned between the second clamp 1048 and the grip1044. As the grip 1044 is coupled (e.g., threaded in the illustratedembodiment) to an end 1053 of the rod 1050 opposite the first clamp1046, the grip 1044 engages the sleeve 1052 to push the second clamp1048 in a direction toward the first clamp 1046. The second clamp 1048thereby moves independently from the first clamp 1046 along the rod 1050toward the first clamp 1046 such that the clamps 1046, 1048 tightlyengage a portion of the gear casing 1033 therebetween to couple the sidehandle 1020 to the power tool.

Referring to FIG. 26, the grip 1044 is illustrated in more detail. Thegrip 1044 includes a substantially hollow body portion 1054 having afirst flange 1056 adjacent a first end portion 1058 and a second flange1060 adjacent a second end portion 1062 spaced apart from the first endportion 1058. A middle portion 1064 of the body 1054 between the flanges1056, 1060 may be texturized or coated with an elastomeric material tofacilitate grasping of the grip 1044. The illustrated grip 1044 alsoincludes a fastener 1066 positioned partially within the body 1054 andcoupled to the body 1054 for rotation with the body 1054. While theillustrated fastener 1066 is a threaded fastener (e.g. bolt), in otherembodiments other suitable types of fasteners may be used. The fastener1066 extends outwardly from the first end portion 1058 of the body 1054and is configured to engage the rod 1050 (FIG. 25). In the illustratedembodiment, the fastener 1066 threadably couples to the end 1053 of therod 1050 to couple the side handle 1020 to gear casing 1033 of the powertool, as further described below. An inner lip 1068 formed inside thebody 1054 maintains the fastener 1066 in place within the body 1054.

The first clamp 1046 is illustrated in more detail in FIGS. 28 and 29.Although only the first clamp 1046 is described below, the first andsecond clamps 1046, 1048 are substantially identical in the illustratedembodiment and, therefore, interchangeable. As such, like parts betweenthe first and second clamps 1046, 1048 have been given the samereference numbers.

As shown in FIGS. 28 and 29, the first clamp 1046 includes a bodyportion 1070 and a leg portion 1072 integrally formed as a single piecewith the body portion 1070. The body portion 1070 includes a passageway1073 having a first portion 1074 that is substantially circular orcylindrical and a second portion 1075 having flat sidewalls 1076. Thefirst portion 1074 of the passageway 1073 is shaped and sized to receivea first portion 1078 of the rod 1050, which is substantially cylindrical(FIG. 30), while the second portion 1075 is shaped and sized to receivea second portion 1079 of the rod 1050 including flat sidewalls 1080(FIG. 30). The leg portion 1072 of the first clamp 1046 is configured tobe received in one of the apertures 1036-1039 of the gear casing 1033 ofthe power tool. In the illustrated embodiment, the leg portion 1072includes a protrusion 1082 configured to fit within the nose portion1042 of the corresponding aperture 1036-1039 to inhibit the clamp 1046from separating from the gear casing 1033.

Referring to FIGS. 30 and 31, the rod 1050 includes the first portion1078, which is cylindrical, and the second portion 1079 having the flatsidewalls 1080. In the illustrated embodiment, the second portion 1079includes two flat sidewalls 1080 that are sized to fit within each ofthe second portions 1075 of the clamps 1046, 1048, which include twoflat sidewalls 1076. The flat sidewalls 1080 of the rod 1050 and theflat sidewalls 1076 of the clamps 1046, 1048 prevent rotation of theclamps 1046, 1048 about the rod 1050 to ensure that the clamps 1046,1048 are properly aligned with one another and, thereby, the apertures1036-1039 in the power tool. The flat sidewalls 1080 of the rod 1050also decrease the size of the second portion 1079 of the rod 1050relative to the first portion 1078 such that a lip 1086 is defined at atransition from the first portion 1078 to the second portion 1079. Thelip 1086 engages a ledge 1088 within the first clamp 1046 to prevent therod 1050 from sliding entirely through the first clamp 1046. In otherembodiments, such as some of the embodiments described below, the firstclamp may be fixed to the rod, such as by welding, interference fit,integrally forming the clamp with the rod, and the like. The rod 1050also includes an inner portion 1090 at the end 1053 configured to couplethe grip 1044 to the rod 1050 by receiving a portion of the fastener1066 of the grip 1044 (FIG. 26).

Referring to FIGS. 25 and 26, the sleeve 1052 is a generally cylindricaltube sized to fit about the first end portion 1058 of the grip 1044 andthe second portion 1079 of the rod 1050. When the grip 1044 is coupledto the rod 1050, the grip 1044 pushes the sleeve 1052 such that thesleeve 1052 engages or pushes against the second clamp 1048 to push thesecond clamp 1048 toward the first clamp 1046. Seated in two of theapertures 1036-1039, the first and second clamps 1046, 1048 tightlyengage, or squeeze, a portion of the gear casing 1033 of the power toolbetween the respective apertures 1036-1039, thereby securely couplingthe side handle 1020 to the power tool. In the illustrated embodiment,the portion 1090 of the rod 1050 is threaded to receive the threadedfastener 1066 of the grip 1044 in order to couple the grip 1044 to therod 1050. In other embodiments, other types and combinations offasteners can be utilized.

To connect the side handle 1020 to the gear casing 1033 of the powertool, the leg portions 1072 of the first and second clamps 1046, 1048are positioned within corresponding apertures 1036, 1037 in the gearcasing 1033, as shown in FIG. 24. If not already partially coupled tothe rod 1050, the fastener 1066 of the grip 1044 is inserted into thesleeve 1052 until the fastener 1066 engages the inner threaded portion1090 of the rod 1050. The grip 1044 is then rotated to threadably couplethe fastener 1066 to the rod 1050.

As the grip 1044 is threaded or rotated into the rod 1050, the grip 1044pushes the sleeve 1052 against the second clamp 1048, and the lip 1086formed on the rod 1050 pushes against the ledge 1088 in the first clamp1046. The first and second clamps 1046, 1048 are thereby pushedtogether. The protrusion 1082 on each clamp 1046, 1048 slides into oneof the nose portions 1042 of the corresponding aperture 1036, 1037. Thegrip 1044 continues to be rotated until the clamps 1046, 1048 tightlyengage a portion of the gear casing 1033 therebetween. Accordingly, whenthe side handle 1020 is coupled to the power tool, the first and secondclamps 1046, 1048 surround only a portion of the circumference of thegear casing 1033. Likewise, if the side handle 1020 was similarlycoupled to the drill 1022 of FIG. 34, the first and second clamps 1046,1048 would only surround a portion of an outer circumference of thechuck 1032. Whereas, if a clamp or clamps surrounded an entirecircumference of the chuck 1032 (e.g., 360 degrees around the axis1034), the user would need to insert the chuck through the apertureformed by the clamps. This can often require aligning multipleprojections or other features of such clamps with recesses in the toolhousing as the user inserts the entire chuck through the clamp or clampsmeanwhile, while also inserting and aligning the chuck, including thebit or the like, through an aperture formed by the clamp. However, inthe illustrated embodiment, the user does not need to insert the chuck1032 through an aperture formed by the clamps. Rather, the user simplyattaches the clamps 1046, 1048 to the top, side, or bottom of the gearcasing 1033 as discussed above.

To remove the side handle 1020 from the power tool, the grip 1044 isrotated in an opposite direction, releasing pressure between sleeve 1052and the second clamp 1048, and thereby between the rod 1050 and theledge 1088 in the first clamp 1046. The second clamp 1048 is then slidslightly away from the first clamp 1046 along the rod 1050 such that theprotrusions 1082 formed on the leg portions 1072 of the clamps 1046,1048 may move out of the nose portions 1042 in the correspondingapertures 1036, 1037.

As shown in FIG. 32, the side handle 1020 may be oriented in a varietyof positions relative to a power tool. In the illustrated embodiment,the side handle 1020 is oriented in a first position and a secondposition relative to the housing, which is the ring 1040 in FIG. 32instead of the gear casing 1033 of FIG. 24. When in the first position,the first and second clamps 1046, 1048 of the side handle 1020 engagethe aperture 1036 and the aperture 1037 of the ring 1040, respectively,such that the grip 1044 would extend outwardly from the power tool 1022in an opposite direction from the grip position illustrated in FIG. 24.When in the second position, the first and second clamps 1046, 1048engage the aperture 1037 and the aperture 1039, respectively, such thatthe grip 1044 would extend substantially downwardly from the ring 1040.The side handle 1020 is capable of being oriented in other positions aswell. For example, the first clamp 1046 may engage any one of theapertures 1036-1039 in either direction to position the side handle 1020in any of eight possible orientations, two of which are illustrated inFIG. 32. Adjusting the orientation of the side handle 1020 relative to apower tool allows the side handle 1020 to be changed for left-handed orright-handed operation of the power tool. In addition, the illustratedside handle 1020 allows the power tool to be quickly and easilyreconfigured for operation in more confined locations.

Various features of the invention are set forth in the following claims.

What is claimed is:
 1. An auxiliary handle for use with a power toolhaving a housing that includes a first notch and a second notch, theauxiliary handle comprising: a shaft; a first clamp coupled to the shaftand having a first protrusion configured to engage the first notch; asecond clamp arranged on the shaft and having a second protrusionconfigured to engage the second notch, wherein when the first protrusionof the first clamp engages the first notch, the second clamp is movablealong the shaft between a first position, in which the second protrusionengages the second notch, such that the auxiliary handle is coupled tothe housing of the power tool, and a second position, in which thesecond protrusion is disengaged from the second notch, such that theauxiliary handle is removable from the housing; and a grip coupled tothe shaft, wherein when the grip is rotated relative to the secondclamp, the second clamp is moved from the second position toward thefirst position.
 2. The auxiliary handle of claim 1, wherein the secondclamp is closer to the first clamp in the first position than in thesecond position.
 3. The power tool assembly of claim 1, wherein thefirst clamp includes a first body portion and a first leg portionextending from the body portion, the first leg, portion including thefirst protrusion.
 4. The power tool assembly of claim 3, wherein thefirst body portion includes a first passageway through which the shaftextends.
 5. The power tool assembly of claim 3, wherein the second clampincludes a second body portion and a second leg portion extending fromthe body portion, the second leg portion including. the secondprotrusion.
 6. The power tool assembly of claim 5, wherein the secondbody portion includes a second passageway through which the shaftextends.
 7. A power tool assembly comprising: a power tool having ahousing that includes a first notch and a second notch; and an auxiliaryhandle including a shaft, a first clamp arranged on the shaft and havinga first protrusion configured to engage the first notch, a second clamparranged on the shaft and having a second protrusion configured toengage the second notch, and a grip coupled to the shaft, whereinrotation of the grip relative to the second clamp causes movement of thesecond clamp toward the first clamp, such that the first protrusionengages the first notch and the second protrusion engages the secondnotch to couple the auxiliary handle to the housing of the power tool.8. The power tool assembly of claim 7, wherein the first clamp includesa first body portion and a first leg portion extending from the bodyportion, the first leg portion including the first protrusion.
 9. Thepower tool assembly of claim 8, wherein the first body portion includesa first passageway through which the shaft extends.
 10. The power toolassembly of claim 8, wherein the second clamp includes a second bodyportion and a second leg portion extending from the body portion, thesecond leg portion including the second protrusion.
 11. The power toolassembly of claim 10, wherein the second body portion includes a secondpassageway through which the shaft extends.